Ok so I have a 1993 FLHS, the fifth gear spline is shot and I am replacing it. I have ordered the parts and Harley has changed the gear so that you buy a set fifth gear and the contershaft gear. All of the old gears have an identification mark on them in the middle of the width of the tooth and all the way around the diameter. The new gears do not have this id mark. Also the new gears are of different shape and more teeth. My question is are these the correct gears? Will they run ok with gears 1 through 4 of the old style?

Thanks for any input.....I don't want to do this 2 times.....

 

Harley changed the design of the gears sometime around `94. The newer gears are called High Contact Gears. These gears can be used in the earlier transmissions, as long as they are used in matched pairs.

Don`t re use the big ball bearing that the main drive gear came out of…The removal of the gear cross loads the bearing. About 20 bucks.

While you are in there, now would be a good time to replace the front belt pulley with the upgraded pulley/spacer/lock/nut (if it has not already been done).

 

Dan, Thanks for the info on the gears.......This problem left me stranded in Ohio las summer. And yes I plan on changing bearings, seals, pulley etc....almost a full rebuild....Have you had any problems with your fith gear spline wearing out?

thanks again

 

Why not just get a 6 speed? How much more can it cost?

 

KBFXDLI,

I looked into that as well, about 3x as expensive and the bike wants to be over 65 mph for 6th gear......Guys I ride with are constantly shifting in and out of 5/6 gear ...no fun for me.....

 

Your pulley nut was probably loose at one time or another, causing the wear on the splines.

 

The splines wearing is a common issue.
Even if the sprocket was not particularly loose, wear can occur.
In fact, if the sprocket is indeed really loose, then the wear tends to transfer to the pulley, more so than the spline.
So in a case where there is a quick transition from tight to loose, the spline can survive quite well, and I have seen that many times.
But slight wear is always evident over time. The only way to prevent that would be a press fit of pulley, and as you know, the pulley actually slides on easily.
It is really important to correctly tension the retaining nut to the maximum.
The locking devices are useful only if positioned to prevent the start of movement, preloaded if you like.
If the nut has even the slightest ability to move before the lock device comes into play, it will fail quickly.